Fastener blanket

ABSTRACT

Fastener blankets disclosed herein can be fitted over each row of the roof and/or wall support members of a building to enclose the fasteners utilized to secure additional building materials to the building structure. The fastener blankets disclosed herein can provide additional insulating R-value properties at the points of the building where the current standard practices provide avenues of significant energy loss. The fastener blankets form a closed shape with the structural member, and at least partially encloses the structural member.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional patent Application Ser. No. 61/086,253, entitled “Fastener Blanket,” filed on Aug. 5, 2008, currently pending, which is incorporated by reference herein in its entirety.

BACKGROUND

Fastener blankets disclosed herein relate to the field of metal building construction, and more particularly to insulation products utilized in metal building construction.

The current practices of providing insulation during construction of metal buildings include the use of rolled batt insulation, rigid board insulation, purlin blocks and/or insulated metal panels. The desired insulation materials are typically incorporated into the roof of a metal building, thought they can be incorporated into the walls of the building as well.

Fasteners, such as screws, nails, bolts or the like, are utilized to secure the building materials to the building structure. Typically, the fasteners utilized to secure the materials to the building structure pass completely through the building materials, including any insulation materials, and extend from the exterior of the building to the interior of the building. These fasteners tend to be made of steel and are conductive. The conductivity of the fasteners results in the fasteners acting as a conduit for heat and cold to transfer through the building, resulting in energy loss.

When batt insulation is used, the insulation is compressed at the fastener locations when the metal roof and wall systems are secured to the building's structure material. This compression results in reduction of the insulating R-value properties of the batt insulation. The compression of the batt insulation at the fastener locations where the insulation is compressed can result in the insulating R-value properties of the batt insulation being reduced to practically zero. When rigid board insulation or insulated metal panels are used to enclose and insulate a metal building, they do not compress like batt insulation. However, the fasteners that extend through the insulation materials still result in energy loss.

BRIEF SUMMARY

Insulation products disclosed herein are fastener blankets that can be utilized in the field of metal building construction. The fastener blankets can be fitted over each row of the roof and/or wall support members of a building. The fastener blankets enclose the fasteners utilized to secure the building materials to the building structure, thus reducing or preventing energy loss due to heat or cold transferred through the fastener.

In one aspect, a fastener blanket to enclose a fastener secured to building structural member is provided that includes a top panel, a first side panel, and a second side panel. The fastener blanket encloses a tip of a fastener attached to a building structural member, and forms a closed shape with the building structural member to which the fastener is attached.

In another aspect, a fastener blanket to enclose a fastener secured to building structural member is provided that includes a top panel, a first side panel, and a second side panel. The building structural member is a purlin, and the fastener blanket encloses a tip of a fastener attached to the purlin. The purlin has a top portion, a vertical portion, and a bottom portion, and the fastener blanket forms a closed shape with the purlin to which the fastener is attached.

In a third aspect, a fastener blanket is provided that includes a top panel, a first side panel including a first bottom end that extends from the first side panel at an angle, and a second side panel including a second bottom end that extends from the second side panel at an angle. The fastener blanket encloses a tip of a fastener attached to a purlin. The purlin has a top portion, a vertical portion, and a bottom portion, and the fastener blanket forms a closed shape with the purlin to which the fastener is attached.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

Specific examples have been chosen for purposes of illustration and description, and are shown in the accompanying drawings, forming a part of the specification.

FIG. 1 is a perspective view of one embodiment of a fastener blanket installed on a purlin.

FIG. 2 is a perspective view of the fastener blanket of FIG. 1, in a stretched state during installation.

FIG. 3 is a cross-section or end view of the installed fastener blanket of FIG. 1.

FIG. 4 is a cross-section or end view of a second embodiment of a fastener blanket installed on a purlin.

DETAILED DESCRIPTION.

Fastener blankets disclosed herein can be fitted over each row of the roof and/or wall support members of a building to enclose the fasteners utilized to secure additional building materials to the building structure. The fastener blankets disclosed herein can provide additional insulating R-value properties at the points of the building where the current standard practices provide avenues of significant energy loss. The fastener blankets encompass the fasteners with an insulating material, which can thus reducing energy loss of the building. The fastener blankets can form a closed shape with the building structural member to which the fastener is attached, and can enclose at least part of the building structural member.

FIGS. 1-4 illustrate two embodiments of the present fastener blankets in an exemplary installation on a purlin. A purlin is a horizontal structural member utilized in constructing the roof of a building. Purlins support the loads from the roof deck or sheathing, and can be supported by the principal rafters, the building walls, or both. In metal building roof systems, purlin members generally have a “Z” shaped cross section, and arc constructed from cold-formed steel. It should be understood that the fastener blankets disclosed herein can also be utilized with other structural members of a building. Preferably, the fastener blankets disclosed herein can be installed by an installer prior to installation of the roof and/or wall system for a building. Once the fastener blanket is installed, the roof and/or wall systems can be installed via standard building practices.

Fastener blankets can be made of any suitable material that has appropriate insulating properties. The dimensions of the fastener blankets, such as height, width and length, can be any suitable dimensions for use in the intended application.

FIGS. 1 through 3 illustrate a first example of a fastener blanket 100 installed on a purlin 102. Fastener blanket 100 has a top panel 104, a first side panel 106 and a second side panel 108. Purlin 102 has a top portion 110, a vertical portion 112 and a bottom portion 114. Roofing materials, including insulation (not shown), can be secured to the top portion 110 of the purlin 102.

When installed, fastener blanket 100 forms a closed shape with the purlin 102, and encloses, or encompasses, at least part of the purlin 102. The cross sectional shape of the closed shape of fastener blanket 100 as installed can any suitable shape, and is preferably a triangle. As illustrated in FIGS. 1 and 3, fastener blanket 100 encloses the top portion 110 and at least part of the length of vertical portion 112 of the purlin 102. For example, the fastener blanket can enclose about half, less than about half or more than about half of the length of the vertical portion 112 of the purlin 102. As illustrated in FIGS. 1 and 3, the fastener blanket encloses more than about half of the of the length of the vertical portion 112 of the purlin 102.

Sections of insulating material, such as purlin block, can be connected to fastener blanket 100. As illustrated first section 118 a of insulating material is connected to the first side panel 106 and second section 118 b of insulating material is connected to the second side panel 108. The sections of insulating material can provide added insulating properties. In examples where purlin blocks are required, and are utilized as the sections of insulating material connected to the fastener blanket, increased labor efficiencies of the building's construction can also be provided.

As illustrated in FIG. 2, the fastener blanket 100 can be installed by flexing the top panel 104 to a flexed position in which the first and second side panels 106 and 108 separate away from each other. During installation, the fastener blanket 100 can be placed in the flexed position, and can be placed over the top portion 110 of the purlin 102. The fastener blanket 100 can then be released so that the fastener blanket 100 achieves its closed position. The fastener blanket 100 can be secured to the top portion 110 of the purlin 102 by one or more fasteners 116, as illustrated in FIGS. 1 and 3.

Once the fastener blanket 100 has been installed, roofing materials can be secured to the top portion 110 of the purlin by additional fasteners 116. As installed, head 120 of a fastener 116 is located above the top panel 104 of the fastener blanket 100 and above top portion 110 of the purlin 102. Typically, the head 120 of fastener 116 is located on the external side of the building, and can be exposed to external weather conditions. The tip 122 of a fastener 116 is located within the interior of the building, and is below the top panel 104 of the fastener blanket 100 and the top portion 110 of the purlin 102. As illustrated in FIG. 3, the tip 122 of a fastener 116 is enclosed by the fastener blanket 100. The insulation provided by the fastener blanket reduces or prevents the fastener 116 from transferring energy between the outside of the building and the inside of the building.

FIG. 4 illustrates a second embodiment of a fastener blanket 200 installed on a purlin 202. Fastener blanket 200 has a top panel 204, a first side panel 206 having a first bottom end 208, and a second side panel 210 having a second bottom end 212. Purlin 202 has a top portion 214, a vertical portion 216 and a bottom portion 218. Roofing materials, including insulation, can be secured to the top portion 214 of the purlin 202. Fastener blanket 200 entirely encompasses the purlin 202.

When installed, fastener blanket 200 forms a closed shape that encompasses the purlin 202. The cross sectional shape of the closed shape of fastener blanket 200 as installed can be any suitable shape, and is preferably a trapezoid. The top panel 204 of the fastener blanket 200 preferably has a width that is greater than the combined width of the bottom ends 208 and 212. The first and second side panels 206 and 210 of the fastener blanket 200 preferably have a length that extends beyond the bottom portion 218 of the purlin 202.

Bottom ends 208 and 212 of the fastener blanket 200 preferably extend towards each other from the first and second side panels 206 and 210, respectively. The first bottom end 208 extends from the first side panel 206 at an angle. As illustrated the angle is greater than about 90°, although in other examples the angle could be about 90°, or less than about 90°. Similarly, the second bottom end 212 extends from the second side panel 210 at an angle. As illustrated the angle is greater than about 90°, although in other examples the angle could be about 90°, or less than about 90°. The first bottom and 208 and the second bottom end 212 extend towards each other, and contact each other at a point below the bottom portion 218 of the purlin 202. First and second bottom ends 208 and 212 of the fastener blanket 200 preferably bend upwards at the point where they contact each other, and can contact bottom portion 218 of the purlin 202.

Sections of insulating material, such as purlin block, can be connected to fastener blanket 200. As illustrated first section 220 a of insulating material is connected to the first side panel 206, and second section 220 b of insulating material is connected to the second side panel 210. First section 220 a of insulating material extends from the top panel 204 of the fastener blanket 200 to the first bottom end 208. Second section 220 b of insulating material also extends from the top panel 204 of the fastener blanket 200 to the first bottom end 208. The sections of insulating material can provide added insulating properties. In examples where purlin blocks are required, and are utilized as the sections of insulating material connected to the fastener blanket, increased labor efficiencies of the building's construction can also be provided.

Similarly to fastener blanket 100, fastener blanket 200 can be installed by flexing the top panel 204 to a flexed position in which the first and second side panels 206 and 210 separate away from each other. During installation, the fastener blanket 200, in the flexed position, can be placed over and around the purlin 202, and can then be released so that the fastener blanket 200 achieves its closed position. The fastener blanket 200 can be secured to the top portion 214 of the purlin 202 by one or more fasteners 222.

Once the fastener blanket 200 has been installed, roofing materials can be secured to the top portion 214 of the purlin 202 by additional fasteners 222. As installed, head 224 of a fastener 222 is located above the top panel 204 of the fastener blanket 200 and above top portion 214of the purlin 202. Typically, the head 224 of fastener 222 is located on the external side of the building, and can be exposed to external weather conditions. The tip 226 of a fastener 222 is located within the interior of the building, and is below the top panel 204 of the fastener blanket 200 and the top portion 214 of the purlin 202. As illustrated in FIG. 4, the tip 226 of a fastener 222 is enclosed by the fastener blanket 200. The insulation provided by the fastener blanket 200 reduces or prevents the fastener 222 from transferring energy between the outside of the building and the inside of the building.

From the foregoing, it will be appreciated that although specific examples have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit or scope of this disclosure. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to particularly point out and distinctly claim the claimed subject matter. 

1. A fastener blanket to enclose a fastener secured to building structural member, the fastener blanket comprising: a top panel; a first side panel; and a second side panel; wherein the fastener blanket encloses a tip of a fastener attached to a building structural member, and forms a closed shape with the building structural member to which the fastener is attached.
 2. The fastener blanket of claim 1, wherein the fastener blanket encloses at least a portion of the building structural member.
 3. The fastener blanket of claim 1, wherein the fastener blanket entirely encloses the building structural member.
 4. The fastener blanket of claim 1, wherein the building structural member is a purlin having a top portion, a vertical portion, and a bottom portion.
 5. The fastener blanket of claim 4, wherein the fastener blanket encloses the top portion and at least part of the vertical portion of the purlin.
 6. The fastener blanket of claim 1, wherein the closed shape that the fastener blanket forms with the building structural member is a triangle or a trapezoid.
 6. The fastener blanket of claim 1, further comprising a first section of insulating material connected to the first side panel.
 8. The fastener blanket of claim 7, further comprising a second section of insulating material connected to the second side panel.
 9. The fastener blanket of claim 8, wherein the first and second sections of insulating material are purlin blocks.
 10. The fastener blanket of claim 1, wherein the fastener blanket is secured to the top portion of the purlin by one or more fasteners.
 11. A fastener blanket to enclose a fastener secured to building structural member, the fastener blanket comprising: a top panel; a first side panel; and a second side panel; wherein the fastener blanket encloses a tip of a fastener attached to a purlin, the purlin having a top portion, a vertical portion, and a bottom portion, and the fastener blanket forms a closed shape with the purlin to which the fastener is attached.
 12. The fastener blanket of claim 10, wherein the fastener blanket encloses at least a portion of the purlin.
 13. The fastener blanket of claim 12, wherein the fastener blanket encloses the top portion and at least part of the vertical portion of the purlin.
 14. The fastener blanket of claim 11, wherein the fastener blanket entirely encloses the purlin.
 15. The fastener blanket of claim 11, wherein the closed shape that the fastener blanket forms with the building structural member is a triangle or a trapezoid.
 16. The fastener blanket of claim 1, further comprising a first section of insulating material connected to the first side panel and a second section of insulating material connected to the second side panel.
 17. The fastener blanket of claim 16, wherein the first and second sections of insulating material are purlin blocks.
 18. A fastener blanket to enclose a fastener secured to building structural member, the fastener blanket comprising: a top panel; a first side panel including a first bottom end that extends from the first side panel at an angle; and a second side panel including a second bottom end that extends from the second side panel at an angle; wherein the fastener blanket encloses a tip of a fastener attached to a purlin, the purlin having a top portion, a vertical portion, and a bottom portion, and the fastener blanket forms a closed shape with the purlin to which the fastener is attached.
 19. The fastener blanket of claim 18, wherein the first bottom end of the first side panel and the second bottom end of the second side panel contact each other at a point below the bottom portion of the purlin.
 20. The fastener blanket of claim 19, wherein the first bottom end of the first side panel and the second bottom end of the second side panel bend upwards at the point where they contact. 